Solid Electrolytic Capacitor with Composite Polymer Layers
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Solution Overview
Problem
Solid electrolytic capacitors using conductive polymers as solid electrolytes face challenges with high equivalent series resistance (ESR) and reduced heat resistance at elevated temperatures, affecting reliability and power consumption.
Innovation Solution
A solid electrolytic capacitor design featuring a dielectric layer with a first conductive polymer layer formed by oxidation polymerization of 2-alkyl-2,3-dihydro-thieno[3,4-b][1,4]dioxine and a second conductive polymer layer formed by oxidation polymerization of 2,3-dihydro-thieno[3,4-b][1,4]dioxine or a mixture, with aromatic sulfonic acid as a dopant, to achieve low ESR and improved heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If 3,4-alkylenedioxy thiophene is used to improve conductivity, then the conductivity is improved, but the heat resistance is significantly decreased
Solution Approach 1:
The patent uses a composite solid electrolyte structure combining two different conductive polymers: poly(2-alkyl-2,3-dihydro-thieno[3,4-b][1,4]dioxine) and poly(2,3-dihydro-thieno[3,4-b][1,4]dioxine). The first polymer provides high conductivity while the second polymer maintains heat resistance, creating a composite material that balances both properties and resolves the contradiction between conductivity improvement and heat resistance degradation.
2Reliability
If 3,4-alkylenedioxy thiophene is used to improve conductivity, then the conductivity is improved, but the ESR becomes large
Solution Approach 1:
The composite structure of two conductive polymers with different properties creates synergistic effects. The first polymer contributes to low ESR through its high conductivity, while the second polymer stabilizes the overall ESR performance. This composite approach resolves the contradiction by distributing the functional requirements across different materials.
3Reliability
If 3,4-alkylenedioxy thiophene is used to improve conductivity, then the conductivity is improved, but the power consumption increases
Solution Approach 1:
The composite polymer structure optimizes the balance between conductivity and energy efficiency. By combining polymers with different electrical characteristics, the solid electrolyte achieves adequate conductivity for capacitor operation while minimizing resistive losses and power consumption through the synergistic properties of the composite materials.
4Reliability
If 3,4-alkylenedioxy thiophene is used to improve conductivity, then the conductivity is improved, but the noise reduction characteristics deteriorate
Solution Approach 1:
The composite structure of two conductive polymers provides balanced electrical properties that simultaneously achieve good conductivity and effective noise reduction. The different polymer components contribute different electrical characteristics that, when combined, filter out noise while maintaining signal transmission, resolving the contradiction between conductivity improvement and noise reduction performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The capacitor exhibits low ESR, excellent heat resistance, and high reliability under high temperature conditions, balancing conductivity and thermal stability.
Implementation Method 1
a first conductive polymer layer is formed by oxidation polymerization of 2-alkyl-2,3-dihydro-thieno[3,4-b][1,4]dioxine as a monomer
Implementation Method 2
As a dopant in performing the chemical oxidative polymerization of the thiophene or its derivatives, organic sulfonic acids can be mainly used
Data Source
AI summary
The present invention provides a solid electrolytic capacitor having a low ESR, excellent heat resistance, and reliability used under a high temperature condition. On the dielectric layer of the capacitor element, 2-alkyl-2,3-dihydro-thieno[3,4-b][1,4]dioxine monomer is subject to oxidation polymerization to provide a first conductive polymer layer. Then, 2,3-dihydro-thieno[3,4-b][1,4]dioxine or a monomer mixture of 2,3-dihydro-thieno[3,4-b][1,4]dioxine and 2-alkyl-2,3-dihydro-thieno[3,4-b][1,4]dioxine is subject to oxidation polymerization to provide a second conductive polymer layer. The formation of the first conductive polymer layer and the second conductive polymer layer is alternatively repeated. The first conductive polymer and the second conductive polymer serve as a solid electrolyte to provide a solid electrolytic.